Weatherstrip assembly apparatus

ABSTRACT

A zig zag wire carrier is continuously formed into a channel shape, and a continuously formed, elastomeric covering strip having a weatherseal element is wrapped around and secured to the channel. The wire channel is guided to straddle an inserter roll, and the body of the covering strip has inturned edges that are spread open by a spreading device as the strip approaches a wrapper adjacent the inserter roll. The wire channel is inserted in between the spread edges of the covering strip, and the wrapper roll presses the covering strip around the wire channel so that the inturned edges of the covering strip are tucked inside the wire channel. Then the legs of the channel are bent inward to complete the product.

fi ment n 1 harming WEATHERSTRW ASSEMBLY APPARATUS lnventor: FrederickJ. Lansing, Rochester,

Assignee: The Schlegel Manufacturing Company, Rochester, NY.

Filed: Apr. 27, 1972 Appl. No.: 248,287

[52] U.S. Cl. 29/202.5

[51] llnt. Cl..... 1323p 19/04 [58] Field of Search 29/202.5, 429, 400R, 29/200 B, 208 D [56] References Cited UNITED STATES PATENTS 2,565,4778/1951 Crowell et a1. 29/202.5

3,529,340 9/1970 Polizzano et al.... 29/202.5

3,689,982 9/1972 Campbell 29/202.5

Primary Examiner-Thomas H. Eager Attorney-Crumpston, Shaw & Stephens[57] ABSTRAUK A zig zag wire carrier is continuously formed into achannel shape, and a continuously formed, elastomeric covering striphaving a weatherseal element is wrapped around and secured to thechannel. The wire channel is guided to straddle an inserter roll, andthe body of the covering strip has inturned edges that are spread openby a spreading device as the strip approaches a wrapper adjacent theinserter roll. The wire channel is inserted in between the spread edgesof the covering strip, and the wrapper roll presses the covering striparound the wire channel so that the inturned edges of the covering stripare tucked inside the wire channel. Then the legs of the channel arebent inward to complete the product.

5 Claims, 17 Drawing Figures FORMER I l t u M l s i z itg g 1 6 5 WCHANNEL J Patented Sept. 4, 1973 8 Sheets-Sheet l mmzmom Juzz Iu az M050Patented Sept. 4, 1973 3,755,873

8 Sheets-Sheet 2 FIG. 2

FIG. 4

53 FIG. 5

PIC-3.6 F|G.7

Patented Sept. 4, 1973 3,755,873

8 Sheets-Sheet 5 Patented Sept. 4, 1973 3,755,873

8 Sheets-Sheet 4 FIG. IO

Patented Sept. 4, 1973 3,755,873

8 Sheets-Sheet 5 8 Sheets-Sheet 6 FIG. I2

Patented Sept. 4, 1973 3,755,873

8 Sheets-Sheet 7 FIG. I?)

Patented Sept. 4, 1973 3,755,873

8 Sheets-Sheet 8 I WEATHERSTRIF ASSEMBLY APPARATUS THE INVENTIVEIMPROVEMENT Weatherstrips suitable for use around the doors and windowsof motor vehicles commonly use a carrier device for gripping an edge tohold the Weatherstrip in place. Many different door and frame shapes,and wide ranges for manufacturing tolerances have required a largenumber of such Weatherstrip constructions.

The invention involves recognition of the possibility of mechanicallyassembling an extruded, elastomeric weather-seal element of the properconfiguration and characteristics with a zig-zag wire carrier formedinto a channel shape, all in one continuous operation for a substantialsaving over previous constructions using different carriers and assemblymethods. The invention aims at simplicity and economy combined withfunctional reliability.

A presently preferred Weatherstrip material is formed of an elastomerthat is extruded to blow into an expanded, closed cellular strip. Thenature of the extrusion process causes considerable variation in thewidth, thickness and resilience of the extruded strip so that it isdifficult to assemble with a carrier. However, the invention suggestsequipment that successfully assembles such an extruded strip with azig-zag wire carrier formed into a channel shape in synchronization withthe extruder for one continuous operation.

SUMMARY OF THE INVENTION The inventive Weatherstrip assembly apparatusincludes means for continuously forming a zig-zag wire carrier into achannel shape, and means for continuously forming an elastomericcovering strip having a weatherseal element and an adjacent body forwrapping around the wire channel. The body of the covering strip hasinturned edges for tucking inside the wire channel. A guide directs thewire channel to straddle an inserter roll for placing the wire channelin the body of the covering strip. A spreader spreads open the body ofthe covering strip to separate the inturned edges, and a wrapper rollwraps the body around the wire carrier so the inturned edges tuck insidethe channel. A guide adjacent the spreader controls the spreading andwrapping of the covering strip, and after the inturned edges of thecovering strip body are tucked into the channel, the legs of the channelare bent inward.

DRAWINGS FIG. I is a partially schematic, elevational view of theinventive assembly apparatus;

FIG. 2 is a fragmentary plan view of the zig-zag wire carrier used inthe inventive apparatus;

FIG. 3 is a crosssectional view of the formed wire channel taken alongthe line 3 3 of FIG. ll;

FIG. 4 is a cross-sectional view of the covering strip used in theinvention and taken along the lines 4 4 of FIG. ll;

FIG. 5 is a cross-sectional view of the covering strip wrapped aroundthe wire channel and taken along the line 5 5 of FIG. 1;

FIG. 6 is a cross-sectional view of the completed product taken alongthe line 6 6 of FIG. 1;

FIG. 7 is a fragmentary, elevational view of a guide for the coveringstrip;

FIG. 8 is a fragmentary, elevational view of a channel guide for theinventive apparatus;

FIG. 9 is a cross-sectional view of the channel guide of FIG. 8, takenalong the line 9 9 thereof;

FIG. 10 is an elevation of the guide and spreader for the machine ofFIG. I;

FIG. 11 is a fragmentary, elevational view of an inserter and wrapperroll for the inventive apparatus;

FIG. 12 is a plan view of the inserter and wrapper rolls of FIG. 10;

FIG. 13 is a plan view of a spreader used in the machine of FIG. I;

FIG. M is an elevation of the spreader of FIG. 13;

FIG. 15 is a fragmentary, elevational view of the position of the wirechannel on the inserter roll;

FIG. 16 is a fragmentary, cross-sectional view of the final forming ofthe wire channel taken along the line 16 16 of FIG. I; and

FIG. 17 is a fragmentary, cross-sectional view of the rollers forsqueezing in the channel legs and taken along the line 17 117 of FIG. 1.

DETAILED DESCRIPTION The main components of the inventive machine 10 areschematically shown in FIG. I. A zig-zag wire carrier Ill, such asillustrated in FIG. 2, is fed to a known channel former 12 havingforming :rolls to shape carrier I ll into a zig-zag wire channel l3 suchas shown in FIG. 3. Meanwhile, an extruder M continuously forms anelastomeric Weatherstrip 15 shown in cross section in FIG. 4.Elastorneric strip 15 is preferably of rubber or rubberlike material andhas closed cells that expand somewhat after leaving extruder 14 to bringstrip 15 to its full dimensions. This expansion is difficult to controlso that the manufacturing tolerances for strip 15 ordinarily vary over arange wide enough to cause assembly problems.

Guides 16 and 17 respectively direct wire channel 13 and covering strip15 toward a guide and spreader I8 arranged adjacent an inserter roll 19and a wrapping roll 20. Details of guide and spreader I8 and inserterand wrapper rolls I9 and 20 are more fully explained below, butgenerally these components work in cooperation to spread open coveringstrip 15, insert wire channel 13 into strip 15, and wrap strip 15 aroundwire channel 13 to secure the two together. The assembled product 2Ileaving inserter and wrapper rolls I9 and 20 is shown in FIG. 5.

A guide 22 directs assembled product 21 to a channel forming roll 23opposite a back-up roll 24 for pressing down on the bottom of the wirechannel to help draw its free legs inward. Then the product 21 passesetween former rolls 25 that press inward against its edges to squeezethe legs of the channel inward to produce the final product 26 having anarrow, gripping channel as shown in FIG. 6.

Considering the process and apparatus in greater detail, zig-zag wirecarrier 11 is formed of a metal or plastic monofilament wire 27 held inazig-zag shape by longitudinal stitching 28 as generally known. Whencarrier lll is formed into wire channel 13 as shown in FIG. 3, it haschannel legs 29 terminating in free end loops 30, and its channel bottom31 is preferably curved convexly inward as illustrated.

Covering strip has a hollow weatherseal element 32 in a generallycircular cross-section and a body 33 for wrapping around channel 13.Body 33 has inturned ends 34 and 35 extending inward along the edges ofbody 33 and divided as illustrated. Covering strip I5 can have manydifferent shapes depending upon the sealing requirements to be met, butgenerally body 33 is sized and shaped for wrapping around channel 13,and weatherseal element 32, which may have a crosssection other thancircular, is adjacent body 32. Strip 15 is preferably formed of anelastomeric and resilient material that is relatively soft andresilient, and preferably is foamed to produce a closed-cell structure.

Guide 17 for directing strip 15 is preferably formed of a low frictionmaterial and has an opening 36 comfortably larger than the cross sectionof strip 15 for steering strip 15 in the desired direction.

Guide 16 of FIGS. 8 and 9 is adjustably mounted on arm 37 and carries aguide block 38 for closing in and directing wire channel 13 without anytwisting of channel 13 from the illustrated upright orientation.

Guide and spreader 18 is best shown in FIGS. and 11, and 13. A guideblock 39 has a channel 40 that steers wire channel 13 accurately withouttwisting so that channel 13 runs astraddle inserter roll 19 as bestshown in FIG. 15. Ledges 41 on inserter roll 19 are positioned toreceive the free loop ends 310 of channel 13 to support channel 13accurately astraddle inserter roll 19.

Underneath guide block 39, a spreader 42 is supported by a screw 43 andspaced from guide block 29 by a spacer 44. Spreader 42 is also shown inplan view in FIG. 13 and in elevation in 1 16. 14. As illustrated inFIG. 10, spreader 42 runs inside body 33 to spread apart inturned edges34 and 35 as illustrated. A fixed guide block 45 adjacent spreader 42assists in the spreading operation, and spreader 42 and guide block 45have different shapes for different cross sections of covering strip 15.Spreader 42 gradually enlarges from its leading end 46 and preferablyextends far enough to straddle wire carrier 13 in the channel 47 in thetrailing end of spreader 42. This assures that inturned edges 34 and 35are held apart and lifted as carrier 13 is inserted in body 33.

Another guide block 48 alongside spreader 42 is preferably verticallyadjustable by means of an adjusting knob 49 and a screw 50. Guide block48 engages weatherseal element 32 as illustrated, and the verticalposition of guide block 48 determines the downward pressure on weatherseal element 32. If body 33 is sufficiently wide for wrapping aroundcarrier 13 without lateral tensioning, then guide block 48 is run in anupper position with very little pressure on seal element 32. However, ifbody 33 is a bit narrow for wrapping around channel 13, then guide block48 is lowered to press down harder on seal 32 and stretch theelastomeric material downward to allow a little more stretch across thebottom of body 33.

inserter roll 19 has a flange 51 that engages seal element 32 as stripis wrapped around carrier 13 straddling inserter roll 19. Seal 32 thenrests between inserter roll 19 and flange 51 and is restrained fromgoing beyond flange 51. Wrapper roll has a ridge 52 that engagescovering strip 15 in the groove between seal element 32 and body 33 forpressing upward on covering strip 15 to wrap inturned end 35 aroundcarrier 13. A channel 53 in wrapper roll 20 forms body 33 around thebottom of channel 13, and a flange 54 opposite ridge 52 engages body 33to push inturned edge 34 up over the edge of channel 13. Then as strip15 and channel 13 leave rolls 19 and 30 they are assembled into aproduct 21 shown in FIG. 5 with inturned ends 34 and 35 tucked inside ofchannel 13. This is facilitated by proper adjustment of guide block 43controlling the lateral stretch of body 33 of strip 15.

Assembled product 21 is then led to a thin former roll 23 opposite aback-up roll 24 having a central groove 55 so that former roll 23 canpress down and flatten the inwardly convex bottom 31 of channel 13. Thistends to bend legs 29 inward, and the groove 55 in back-up roll 24prevents pressure from forming, and roll 23 from cutting through body33.

Beyond former roll 23, a pair of preferably driven rolls 25 engageopposite sides of the assembled product and squeeze inward asillustrated in FIG. 7 to bend channel legs 29 further inward to producethe finished product 26 shown in FIG. 6. The relatively closed channel13 carrying inturned ends 34 and 35 can then be pressed over an edgearound an automotive door or window to hold weatherseal 32 in properposition for sealing. The Weatherstrip retains itself in proper positionwith inturned ends 34 and 35 providing a frictional grip, and wirechannel 13 providing a resilient squeeze. Seal element 32 then bridgesgaps between a door and frame and yieldably engages both the door andthe frame for an effective seal.

The inventive apparatus allows continuous and economical formation of aWeatherstrip having a preferred soft and elastomeric cover over aspringy, wire carrier channel. Such combination has many advantages offunctional and economic significance, and the inventive apparatus allowsthe product to be made at high speeds and accuracy.

Persons wishing to practice the invention should remember that otherembodiments and variations can be adapted to particular circumstances.Even though one point of view is necessarily chosen in describing anddefining the invention, this should not inhibit broader or relatedembodiments going beyond the semantic orientation of this applicationbut falling within the spirit of the invention. For example, thoseskilled in the art will appreciate the different Weatherstripconfigurations that can be made on the inventive apparatus, and willunderstand different drives, guides, spreaders and roll shapes forassembling any desired weather seal according to the invention.

I claim:

1. Weatherstrip assembly apparatus comprising:

means for continuously forming a zig-zag wire carrier into a channelshape;

b. means for continuously forming an elastomeric covering strip having aweatherseal element and an adjacent body for wrapping around said wirechannel, said body having inturned edges for tucking inside said wirechannel;

0. an inserter roll for placing said wire channel in said body of saidcovering strip;

d. a guide for directing said wire channel to straddle said inserterroll;

e. a wrapper roll for wrapping said body around said wire carrier sosaid inturned edges tuck inside said channel;

f. said wrapper roll being adjacent said inserter roll;

g. a spreader arranged in the region of the approach of said coveringstrip to said wrapper roll for spreading open said body of said coveringstrip;

h. said spreader straddling said wire carrier on said inserter roll;

varying the lateral stretching tension on said body.

4. The apparatus of claim ll wherein the bottom of said Wire channel isinwardly convex, and said means for bending the legs of said channelinward includes a thin roller for bending said channel bottomsubstantially flat.

5. The apparatus of claim 4i including side rollers for squeezing thelegs of said channel inward after flattening of said channel bottom.

Pk t WK l t

1. Weatherstrip assembly apparatus comprising: means for continuouslyforming a zig-zag wire carrier into a channel shape; b. means forcontinuously forming an elastomeric covering strip having a weathersealelement and an adjacent body for wrapping around said wire channel, saidbody having inturned edges for tucking inside said wire channel; c. aninserter roll for placing said wire channel in said body of saidcovering strip; d. a guide for directing said wire channel to straddlesaid inserter roll; e. a wrapper roll for wrapping said body around saidwire carrier so said inturned edges tuck inside said channel; f. saidwrapper roll being adjacent said inserter roll; g. a spreader arrangedin the region of the approach of said covering strip to said wrapperroll for spreading open said body of said covering strip; h. saidspreader straddling said wire carrier on said inserter roll; i. a guideadjacent said spreader for engaging and guiding said weather sealelement; and j. means for bending the legs of said channel inward aftersaid inturned edges of said body are tucked into said channel.
 2. Theapparatus of claim 1 wherein said inserter roll has ledges radiallyinward from the periphery of said inserter roll for supporting the freeends of said wire channel in said straddling position on said inserterroll.
 3. The apparatus of claim 1 including means for verticallyadjusting said guide adjacent said spreader for varying the lateralstretching tension on said body.
 4. The apparatus of claim 1 wherein thebottom of said wire channel is inwardly convex, and said means forbending the legs of said channel inward includes a thin roller forbending said channel bottom substantially flat.
 5. The apparatus ofclaim 4 including side rollers for squeezing the legs of said channelinward after flattening of said channel bottom.